Post torrefaction biomass pelletization

ABSTRACT

A process for torrefaction of biomass is provided in which biomass are passed into a fluidized bed or a non-fluidized bed reactor and heated to a predetermined temperature in an oxidizing environment. The dried biomass is then fed to a cooler where the temperature of the product is reduced to approximately 100 degrees Fahrenheit.

This application is a continuation of U.S. patent application Ser. No.13/665,886, (“the '886 Application”) filed on Oct. 31, 2012, whichclaimed the benefit of U.S. Provisional Application Ser. No. 61/555,856,filed Nov. 4, 2011, the entire disclosures of which are incorporated byreference herein. The '886 Application is also a continuation-in-part ofU.S. patent application Ser. No. 13/084,697, filed Apr. 12, 2011, whichissued as U.S. Pat. No. 8,956,426 on Feb. 17, 2015, which is aContinuation In Part of U.S. patent application Ser. No. 12/763,355,filed Apr. 20, 2010, the entire disclosure of each is incorporated byreference herein.

FIELD OF THE INVENTION

Embodiments of the present invention generally relate to thermalprocessing of biomass “torrefaction” so that it can be used instead of,or in addition to, fossil fuels for energy production thereby reducingthe carbon footprint. In one embodiment of the present invention, thebiomass is “roasted” in the presence of oxygen wherein heat generated bythe combustion of biomass and hot gases associated with biomasscombustion provide the heat required to support thetorrefaction/roasting process, all in a single reactor.

BACKGROUND OF THE INVENTION

Many states have adopted Renewable Portfolio Standards (RPS) thatrequire electricity supply companies to increase energy production thatis attributed to renewable energy sources. The federal government maysoon implement a renewable electricity standard (RES) that would besimilar to the “renewables obligation” imposed in the United Kingdom.These standards place an obligation on electricity supply companies toproduce a specified fraction of their electricity from renewable energysources, such as wind, solar, hydroelectric, geothermal, biofuels, andbiomass.

“Biomass” refers to renewable organic materials such as wood, forestrywaste, energy crops, municipal waste, plant materials, or agriculturalwaste. Biomass often contains about 10 to about 50 weight percentmoisture and up to about 50 weight percent oxygen. The moisture andoxygen content in raw biomass decreases its fuel value and increasescosts associated with transportation of the biomass. Thus biomass is alow grade, high cost fuel that cannot compete economically with fossilfuels most commonly used to generate electricity. Further, biomass has alow bulk density, is very hydrophilic, can be seasonal, is variable, andhas a limited shelf life.

“Torrefaction” refers to the processing of biomass at temperaturesbetween about 200° C. to about 350° C. (400°−660° F.) at atmosphericpressure wherein water and light volatile organic chemicals associatedwith the raw biomass material (i.e., “feed stock”) are vaporized. Inaddition, during the torrefaction process, molecules of biopolymers(hemicelluloses and some lignin) contained in the biomass decompose.After torrefaction, the biomass is a solid, dry, blackened material thatis often referred to as “torrefied biomass” or “biocoal” that is easierto grind than raw unprocessed biomass and has a heating value comparableto low-rank coals, which allows it to be used in coal burning powerplants without any major equipment modifications or plant capacityderate. Further, the torrefied biomass has a significantly, reducedmoisture content, and has higher fixed carbon levels.

Fluid bed reactors are commonly used to carry out multiphase reactions.In this type of reactor, gas or liquid is passed through a granularsolid material at high enough velocity to suspend the solid and cause itto behave as though it were a fluid. This process, known as“fluidization” imparts many important advantages to the reactor. As aresult, the fluidized bed reactor is now used in many industrialapplications, such as coal drying. Commonly coal drying is performed inan inert gas, i.e., oxygen-free environment. Drying coal in anon-oxidizing environment requires external heat sources to maintain thetemperature of the reactor. However, coal has been dried in an oxidizingenvironment where the heat used to support the process is at leastpartially drawn from the burning coal. The temperature of the fluid bedreactor used to dry and otherwise process the coal is controlled bybalancing the rate at which the coal is fed into the reactor against theamount of heat generated by the combustion process. Drying of coalincreases the heating value of low rank coals, reduces the particle sizeof the feed stock, and partially decarboxylizes and desulfurizes thecoal. After the coal is dried, it must be rehydrated to raise themoisture content up to about 5-9% to reduce its spontaneous combustioncharacteristics so that it is similar to native coal.

The table provided below illustrates the differences between raw coaland processed coal. One of skill in the art will appreciate thatprocessed coal possesses a higher fixed carbon and heating valuescorrespond to raw coal and the moisture content is drastically reduced.

Raw Coal Product 1 Product 2 Product 2 Proximate Analysis: Moisture20.16%  8.00%  8.00%  8.00% Ash  8.16%  7.93%  8.69%  8.67% VolatileMatter 31.70% 35.33% 34.90% 35.05% Fixed Carbon 39.98% 48.74% 48.42%42.48% Ultimate Analysis: Moisture 20.16%  8.00%  8.00%  8.00% Hydrogen 2.87%  3.32%  3.19%  3.14% Carbon 55.50% 63.15% 62.65% 62.74% Nitrogen 0.75%  0.99%  1.12%  0.81% Sulfur  0.77%  0.52%  0.54%  0.48% Oxygen11.79% 16.09% 15.82% 16.16% Ash  8.16%  7.93%  8.69%  8.67% HeatingValue, Btu/lb 9,444 10,460 10,315 10,165

Fluidized bed processing of biomass has similar effect on the biomassproduct (biocoal). Further, for certain straw-like biomass, and possiblywoody biomass residue, it is advantageous to pelletize biomass beforetorrefaction. Resulting torrefied product has bulk properties similar tothat of coal, i.e., grinds easier and is easier to handle. Often,however, a binding agent, such as lignin, which also naturally occurs inthe biomass, must be added to pulverized raw biomass so that pellets orbriquettes (used in some instances interchangeable herein) can beformed. Often, pellets are formed in extrusion operation whereasbriquettes are made in a pressing operation. The following patents andpublished patent applications describe raw biomass pelletizing processesof the prior art.

-   -   1) US 2008/0190015 A1—Describes that pellets can be formed from        raw biomass on the basis of pressure with no regard to lignin        content of the biomass.    -   2) U.S. Pat. No. 4,308,033—Describes grinding biomass to an        unspecified size, drying the biomass to 13% moisture or less,        adding a wax-water emulsion or a wax-lignin mixture to provide        supplemental binder, adjusting the binder-biomass mixture        moisture to approximately 28% moisture, and pelletizing the        material in a conventional pellet press.    -   3) “Densification characteristics of corn cobs”, N Kaliyan and R        Morey—This study found that corn cobs at a moisture content of        approximately 10% would form a good quality briquette/pellet at        a temperature of approximately 85° C. (185° F.) and a pressure        of 150 MPa (21,756 psi).    -   4) “Natural binders and solid bridge type binding mechanisms in        briquettes and pellets made from corn stover and switchgrass”,        Bioresource Technology 101 (2010) 1082-1090, N. Kaliyan and R.        Morey—This publication studied the binding mechanisms of natural        binders found in corn stover and switch grass and found that        natural binders softened at a temperature between 50° C. and        113° C. (122° F. and 235° F.). Moisture contents were in the        range of 10% to 20%. Material tested was ground to corn stover        particle size equal to about 0.34 mm and switch grass particle        size equal to about 0.49 mm.    -   5) US 2009/0205546 A1—Describes that pellets can be made using a        mixture of at least 75 weight percent cellulosic materials        (biomass) and 5 to 15 weight percent thermoplastic polymeric        materials. The temperature of the thermoplastic polymeric        material may be raised to between 140° C. and 145° C. (284° F.        and 293° F.) before or during mixing. The mixture is then        pelletized and cooled. Thermoplastic polymeric materials are        described as polyethylene, polypropylene, polyamide, polyimide,        or combinations thereof    -   6) US 2010/0206499 A1—Describes the conversion of a pulp        processing plant to a biomass based pellet manufacturing plant.        The biomass feed is first processed by a convention pulp        digester. This digester liberates the lignins present in the        biomass. The pulp from the digester is then recombined with the        liberated lignins and then pelletized. No pelletizing conditions        are described.    -   7) “Feedstock and Process Variables Influencing Biomass        Densification”, Mark Shaw Master of Science Thesis—This document        evaluated the affect of pressure and temperature on biomass        pellet quality. Test work was completed using poplar wood and        wheat straw and included various pressures between 31.6 and        126.3 MPa (4.6 and 18.3 psi) and temperature between 70 and        100° C. (158 and 212° F.). Moisture contents of the feed were 9        and 15%. This work also made an evaluation of the effect of        pre-treating the biomass with steam expansion. A number of        trends were indicated by this work but no definitive direction        was offered on how to make a quality pellet. The overall        conclusions are that 1) chemical composition of the feed stock        did not have a large impact on compression/compaction, and 2)        particle size and moisture content have more significant impact        on compression and compaction than chemical composition.

Note that most these references are concerned with pelletizing rawbiomass, and in some instances pulp, not torrefied biomass. Morespecifically, torrefaction significantly reduces the presence ofhemicellulose compounds, to a lesser degree lignins, and thus torrefiedbiomass would be expected to pelletize differently than raw biomass orpulp and thus would be subjected to different pelletizing processes andrequirements.

More specifically, attempts to pelletize torrefied biomass have revealedthat a glassy surface forms on the exterior surface of the pellets whenpelletization is performed in the range of about 121 to 135° C.(250-275° F.) as measured after the pellet was discharged from a Blisspellet mill. Because in one test there was a one or two minute delaybetween pellet production and because the actual temperature conditionsof the pellet press is higher than ambient, it is believed thatpelletization temperature may have been higher. The glassy surfaceappears to be due to surface porosity sealing that impartshydrophobicity to the pellet which enhances resistance to waterdegradation.

The pellets produced in one test were made from fines collected by acyclone used in torrefaction process. The fines appear to be more evenlytorrefied than the average processed biomass product consisting oflarger particles. The fines were heated to approximately 135° C. (275°F.) and pressed into pellets. The resultant pellet appeared to be muchdenser than those observed in previous attempts to form pellets at lowertemperatures. The pressed pellet did not have a glassy surface that wasobserved when the final torrefied biomass product was pelletized usingring-die pelletizing machine. No attempt was made to evaluate thispellet to determine its hydrophobic nature or resistance to waterdegradation, however. One of skill in the art will appreciate thatpressed pellet does not have the same surface characteristics as theextruded pellet from a ring-die machine.

The work by others in an attempt to pelletize torrefied biomass appearsto be under conditions similar to that used by traditional wood pelletprocesses, which typically restrict it to temperatures of about 65-93°C. (150-200° F.). However, under those conditions, the pellets are nothydrophobic and tend to degrade when exposed to moisture unlessadditional binders are added. As one of skill in the art willappreciate, adding binders adds additional production steps and costs.

SUMMARY OF THE INVENTION

It is one aspect of the present invention to process biomass bytorrefaction. More specifically, torrefying biomass is an efficient wayto achieve the goal of producing a biomass material that can be handledand burned like coal. Thus one embodiment of the present invention is atorrefaction process that is suited for biomass that reduces themoisture content, increases the heating value (HHV), and improvesgrindability and handling characteristics of the biomass.Hydrophobicity, shelf life, energy density, and homogeneity are all alsoimproved. In addition, mass recovery of 55-65% of the feed as salableproduct is achieved. Further, energy recovery in the range of about80-85% of the feed energy content of product is provided where nearlyall sulphur is removed. In the process of one embodiment of the presentinvention, about 70% of the chlorine in the feed is also removed. Oneadvantage to the contemplated process and related systems is that theprocessed biomass can be used in existing fossil fuel burning powerplants alone or in combination with fossil fuels. That is, little or nomodifications are needed to existing power producing systems orprocesses, and generating capacity was not decreased (derated).

It is another aspect of the present invention to employ a fluid bedreactor to torrefy the biomass. In one embodiment, the fluid bed reactoruses a combination of air and gas drawn from the fluid bed exhaust,i.e., “offgas” as a primary heating and fluidizing gas. The rate offluidizing gas introduction into the fluid bed reactor would be asrequired to produce a gas velocity within the fluid bed reactor betweenabout 4 and 8 feet per second. At this velocity, the bed temperature ofthe reactor would be maintained between about 230 to 350° C. (450 to670° F.).

It is another aspect of the present invention to employ non fluidizedbed reactors such as rotating drums, rotary kilns, cascaded whirling beddryers, elongated slot dryers, hopper dryers, traveling bed dryers,vibrating fluidized bed dryers, vibrating screens, screw-based reactorsand alike to torrefy the biomass. In such embodiments, the reactor usesa combination of air and gas drawn from the reactor exhaust, i.e.,“offgas” as a primary heating and carrier gas for materials removed fromthe feed during torrefaction. The temperature of the reactor ismaintained between about 230 and 350° C. (450 to 670° F.).

It is still yet another aspect of the present invention to torrefybiomass in the presence of oxygen. More specifically, as those skilledin the art are aware, torrefaction processes of biomass and coal, havegenerally been performed in an inert environment, usually in thepresence of nitrogen, argon, water vapor, or some other inert orreducing gas. Those of skill in the art are also familiar with the factthat the rate at which volatiles associated with the feed stock areconverted to vapor is a function of the amount of volatile organic andinorganic chemicals, processing temperature, and the residence time atthe processing temperature. In general, reaction rates for volatileevolution, thermal cracking of larger organic compounds, and oxidationof the biomass increase with the increasing temperatures and increasedresidence time. However, because it takes time to dry the materialbefore torrefaction reactions can occur, if the biomass is predried,preferably using heat from other sources in the system, residence timescan be reduced.

Torrefying in an oxygen rich environment adds to the conversion of solidmass to gaseous mass and generates energy to drive the torrefactionprocess. The combustion of vaporized volatiles driven from the biomassgenerates heat to help maintain the torrefaction process. Traditionally,the heat associated with torrefaction predominately originates fromoutside sources. In contrast, the system of one embodiment of thepresent invention employs a fluid bed reactor that is heated internallyby the burning of vapors from biomass and biomass itself. This reducesthe amount of energy required from outside sources and allows thebiomass to be “roasted” economically and in a controlled manner.

The primary reason that torrefaction processes of the prior art areperformed in an inert environment is that burning of the biomass isbelieved to be uncontrollable and could lead to an explosion.Embodiments of the present invention, however, control the heatgeneration in the reactor to prevent excess combustion rates andpossible explosion. Temperature control is achieved by controlling theamount of biomass feed and the amount of available oxygen to the reactorand one embodiment of the invention, combustion rate within the reactoris also controlled by selectively adding water to the reactor.

It is another aspect of the present invention of some embodiments of thepresent invention to use alternate forms of biomass, such as switchgrass, agricultural waste, or sawdust, that are not suitable forprocessing in a fluid bed reactor. That is, normally unsuitablecellulosic biomass is first sized and shaped into a predetermined formto allow processing by the reactor. One method of performing thisresizing is achieved by using an Andritz-Sprout pellet mill.

It is another aspect of the present invention to provide a torrefactionprocess that employs a rotary drum reactor. In one embodiment, thebiomass flows countercurrent to the flow of reaction gas, e.g. recycledgas and air. The gas directed to the reactor must be sufficient tomaintain the necessary oxygen level and so that volatile combustion rateproceeds at a rate to produce sufficient heat to torrefy the biomasswithout becoming uncontrolled.

It is another aspect to provide a scalable system. As traditionalsystems depend primarily on external heat sources, increase in reactorsize translates to reduced external surface area to volume ratios,thereby requiring increased heat transfer rates or reduced capacity. Asone skilled in the art will appreciate, in the case of a large reactor,external heating sources cannot efficiently raise the temperature of theinner portions of the larger reactors to heat the biomass efficiently.

The reactors of embodiments of the present invention, however, can beincreased in size because the heat needed for torrefaction is internallygenerated. Ideally, a large reactor having an increased diameter isdesired because it provides a bed with a large surface area to evenlyexpose the biomass to the heat.

It is still yet another aspect of the present invention to provide aprocess where pre-drying is used. As briefly mentioned above, biomass isoften wet having a moisture content of about 10-50%. Thus to decreaseresidence time within the fluid bed reactor that is associated withvaporizing such moisture, some embodiments of the present inventionpre-dry the feed stock. Pre-drying also increases the consistency of thefeedstock which promotes consistent reactor operation. Pre-drying can beachieved by simply allowing the biomass to dry under ambient conditions.More preferably, however, a controlled pre-drying process is usedwherein excess heat from the fluid bed reactor, or other processingstations of the system, is used to pre-dry the biomass.

It is still yet another aspect of the present invention to provide aprocess for starting combustion in the fluid bed reactor. Morespecifically, one embodiment of the present invention uses excess heatto initially start combustion of a predetermined amount of biomasspositioned within the fluid bed reactor. After combustion has begun, theheat within the fluid bed reactor will increase due to the combustion ofthe biomass product. Once the temperature in the fluid bed reactorreaches a predetermined level, the amount of external heat added to thefluid bed reactor can be decreased and additional biomass is added tothe reactor to maintain the temperature of the fluid bed reactor.

It is another aspect of the present invention to provide a newprocessing environment where torrefaction is performed at about 290° C.(550° F.) and wherein the biomass has a 15-20 minute residence time. Oneembodiment of the present invention has a minimum auto reactiontemperature of about 260° C. (500° F.) and produces off gases of about10 to 17 volume percent water vapor and about 4 to 5 volume percentcarbon dioxide. The pressure in the fluid bed reactor is nearatmospheric.

It is yet another aspect of the present invention to employ water spraysand a mixing device, such as a mixing screw or rotary drum, to cool theprocessed biomass. Hot torrefied product would be discharged directlyfrom the reactor into the cooler and water would be sprayed onto the hotproduct through the use of a multiplicity of sprays to provide coolingthrough evaporation of water. The total amount of water added would bethat to provide cooling to approximately the boiling point of water(100° C. at sea level) without raising the moisture content of thecooled product above approximately 3 weight percent. The mixing/tumblingaction of the cooler would provide particle to particle contact toenhance distribution of the water added for cooling. The directapplication of water may be achieved by methods disclosed in U.S. patentapplication Ser. No. 12/566,174, which is incorporated by reference inits entirety herein.

In an alternative embodiment of the present invention, an indirectcooler to reduce the temperature of the torrefied biomass is employed inthe event that a minimum moisture content is required. For example, anindirect cooler with cooling surfaces such as a hollow flight screwcooler or a rotary tube cooler may be employed to achieve this goal.

It is another aspect of the present invention to provide a single stageprocess for biomass torrefaction, comprising charging biomass to afluidized bed reactor, charging air to the fluidized bed reactor at avelocity of from about 4 to about 8 feet per second, subjecting thebiomass to a temperature of from about 230 and 350° C. (450 to 670° F.),and removing the water from the biomass by torrefying the biomass. Thebiomass charged to the fluidized bed reactor of this embodiment hasaverage moisture content from about 10 to about 50 percent. The reactorof this example may be comprised of a fluidized bed with a fluidized beddensity up to about 50 pounds per cubic foot. In one contemplatedprocess wood chips having a density of about 10 to 13 pounds per cubicfoot are used. At fluidization, the bed density would be no more thanhalf of the density of the feed stock. The biomass, such as agriculturalwaste, straw-like energy crops, etc., may be pelletized before feedinginto the reactor. Pelletized feed would have bulk density of about 40pounds per cubic foot so its bed density would be about 20 pounds percubic foot.

It is another aspect of the present invention to provided a process forbiomass torrefaction, comprising: adding biomass to a reactor; addingenriched gas to said reactor; controlling the oxygen content of theenriched gas; initiating heating of said biomass by increasing thetemperature of said reactor; heating said biomass; maintaining saidbiomass within said reactor for a predetermined time; removing waterfrom said biomass; vaporizing volatile organic compounds associated withsaid biomass; torrefying said biomass; and combusting said volatileorganic compounds to help maintain the temperature of said fluidized bedreactor.

It is still yet another aspect of the present invention to provide aprocess for drying a material, comprising: directing the material to areactor; pre-drying the material with gasses exhausted from thefluidized bed reactor; and subjecting said material within the reactorto a temperature sufficient to evaporate water; and combusting thevaporized organic compounds to provide heat needed to help maintain saidtemperature.

It is another aspect of the present invention to provide a torrefactionprocess that includes torrefaction of straw-like biomass by firstpelletizing the biomass and then torrefying the pellets.

It is another aspect of the present invention to provide a torrefactionprocess that includes high pressure densification of the torrefiedbiomass into pellets or briquettes. More specifically, in one embodimentof the present invention, torrefied biomass is formed into a pelletusing a pelletizing device wherein the pelletizing process is performedat about 90°-200° C. (194°-392° F.), and more preferably about 93°-177°C. (200°-351° F.). The unit density of pellets formed using this processis expected to be about 3-5 times greater than the density of thetorrefied biomass prior to pelletization. Bulk density is increased by2-4 times. The high pelletizing temperatures contemplated mobilize andredistribute lignins, i.e., natural binders still present in thetorrefied biomass. As lignins and other natural binding agents areplentiful in non-processed biomass, pelletization can be performed atlower temperatures. In addition, the contemplated process is ideal forbiomass materials that do not have sufficient natural binders whichwould form pellets with unacceptable hydrophobicity, regardless of theamount of heat provided during pelletization. In such cases, high heatenvironment will significantly reduce the amount of supplemental binderrequired.

It has been found that by pelletizing at a higher temperature, anyremaining lignins in the torrefied biomass would become sufficientlyplastic so as to produce a suitably hydrophobic pellet with minimal orno supplemental binder required. The higher pelletizing temperaturesalso increase plasticity and reactivity, which promote the creation of acoating on the outside of the pellet that helps the pellet resist theeffect of the moisture. Further, if any binders are added when thebiomass is processed at these high temperatures, the resultant pelletshave improved mechanical properties and resist degradation when exposedto moisture because the binders are used more efficiently. One of skillin the art will appreciate that lignins, which are sometimescharacterized as thermoplastic materials experience lower viscosity astemperature increases.

Further, although it is desirable to avoid using a binder, one of skillin the art will appreciate that binders may be used to 1) improve themechanical strength of the pellet; 2) provide lubrication to controlpress temperature and to enable high throughput; 3) increasepolymerization reactions of natural binders present in the biomass; 4)improve hydrophobic properties; 5) modify thermoplasticity of naturalbinders; and 6) modify ash melting temperature of constituents such asalkali metals present in the biomass.

In one embodiment, the high pelletizing temperatures are obtained bymaintaining the temperature of the torrefied biomass discharged from thereactor. To accommodate such high temperature pelletization, closecoupling of pelletizing equipment and reactor inconjunction withequipment insulation and/or jacketed transfer equipment with suitableheating fluid circulation may be required. In addition to, or insteadof, not letting the torrefied biomass to cool, the torrefied biomass maybe reheated before or during the pelletization process. One of skill inthe art will appreciate that reheating the torrefied biomass may beaccomplished using jacketed equipment with suitable heating fluidcirculating in the jacket and/or heat taken from frictional forcespresent within the press. Alternatively, the heat may be provided byexposure with hot fluid gas, e.g., on a belt dryer or storage bin thatis operated as a down draft fixed bed. Further, a combination of heatingor heat conservation techniques may be used.

Traditional wood pelletizing operations avoid high temperatures byincreasing the moisture content of the biomass or using jacketed pressequipment that cools the press dye to a controlled temperature so as toavoid the onset of biomass devolitization at temperatures above, forexample, about 130° C. As embodiments of the present invention areconcerned with torrefied biomass, devolitization is not an issue. Theheating approach used by embodiments of the present invention may alsodepend on press design parameters, so one specific heating approach maynot be suitable for all press designs. After forming the hightemperature pellets, the pellets would be cooled to provide pelletstrength for bulk storage and loadout.

It is another aspect of the present invention to provide a torrefiedbiomass pellet having a coating. In one embodiment, the pellets aregenerally cylindrical with a diameter of about 0.25 inches with varyinglength.

It is another embodiment of the present invention to use an inexpensiveadditive such as coal to pelletize torrefied biomass. Just like ligninsin the biomass, tars present in the coal act as a binder.

The Summary of the Invention is neither intended nor should it beconstrued as being representative of the full extent and scope of thepresent invention. Moreover, references made herein to “the presentinvention” or aspects thereof should be understood to mean certainembodiments of the present invention and should not necessarily beconstrued as limiting all embodiments to a particular description. Thepresent invention is set forth in various levels of detail in theSummary of the Invention as well as in the attached drawings and theDetailed Description of the Invention and no limitation as to the scopeof the present invention is intended by either the inclusion ornon-inclusion of elements, components, etc. in this Summary of theInvention. Additional aspects of the present invention will become morereadily apparent from the Detail Description, particularly when takentogether with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate embodiments of the invention andtogether with the general description of the invention given above andthe detailed description of the drawings given below, serve to explainthe principles of these inventions.

FIG. 1 is a schematic representation showing the relationship betweenbiomass, coal, and charcoal torrefaction;

FIG. 2 is a schematic of a biomass torrefaction process of oneembodiment of the present invention;

FIG. 3 is a detailed view of FIG. 2 showing a fluid bed reactor used inthe process of one embodiment of the present invention;

FIG. 4 is a table showing wood biomass data;

FIG. 5 is a table showing bio-coal data; and

FIG. 6 is a schematic showing torrefied biomass processing options.

To assist in the understanding of one embodiment of the presentinvention, the following list of components and associated numberingfound in the drawings is provided below:

# COMPONENT

-   -   2 Biomass torrefaction system    -   6 Fluid bed reactor    -   10 Hopper    -   14 Conveyor    -   18 Surge bin    -   22 Feeder    -   26 Feed screw    -   34 Plate    -   46 Off gas    -   50 Startup heater combustion air fan    -   54 Recycle fan    -   58 Recycle Gas line    -   62 Recycle Gas line    -   66 Recycle Gas line    -   70 Heated Fluidizing Gas line    -   74 Heated Fluidizing Gas line    -   78 Heated Fluidizing Gas line    -   82 Offgas line    -   86 Recycled Gas line    -   90 Recycled Gas line    -   94 Fresh air fan    -   98 Valve    -   102 Emissions control device    -   106 Particulate removable device    -   110 Startup heating system    -   114 Valve    -   118 Cooler    -   122 Dump valve    -   126 Conveyor    -   130 Storage system    -   140 Grinder    -   144 Pelletizer/Briquetter    -   146 Pellet Cooler    -   150 Pellet Cooling Fan

It should be understood that the drawings are not necessarily to scale.In certain instances, details that are not necessary for anunderstanding of the invention or that render other details difficult toperceive may have been omitted. It should be understood, of course, thatthe invention is not necessarily limited to the particular embodimentsillustrated herein.

DETAILED DESCRIPTION

FIG. 1 is a schematic representation showing the relationship betweenbiomass, coal, and charcoal. It is one goal of embodiments of thepresent invention to provide a system and process suited for alteringbiomass, regardless of its source, such that it behaves like coal. Oneadvantage of providing biomass that behaves like coal is that existingcoal burning electrical power plants can use the processed biomasswithout substantial modifications. To make biomass a viable alternative,moisture content must be reduced, heating value must be increased,grindability and handling must be improved, hydrophobicity must beimparted, shelf life must be increased, energy density must beincreased, and homogeneity must be improved. To achieve theseobjectives, embodiments of the present invention treat biomass bytorrefaction wherein water, light volatile organic chemicals, sulfur,and chlorine are driven out of the raw biomass. The end result is a coallike product that can be used in coal burning electricity generationplants of current design.

More specifically, the torrefaction contemplated by embodiments of thepresent invention include thermally processing biomass at temperaturesof about 250-325° C. (480-620° F.) under near atmospheric pressure andin the presence of oxygen. This process will remove water and lightvolatiles from biomass and will reduce the oxygen content of thebiomass. Importantly, the amount of fixed carbon in the biomass isincreased and the biopolymers, hemicelluloses, and some lignin, aredecomposed.

Referring now to FIG. 2, the biomass torrefaction system 2 of oneembodiment of the present invention employs a fluidized bed reactor 6.The biomass may be wood that has been reduced in size by a commerciallyavailable wood chipper. The biomass may also be pelletized to improveits size, shape, and/or bulk density. The size of the biomass will vary,but the smallest dimension is typically about 3 mm to 10 mm. Althoughwood is mentioned here, one of skill in the art will appreciate thatstraw or other agricultural waste may be used without departing from thescope of the invention. In one embodiment, biomass having about 10 to 50weight percent moisture is processed. The biomass is initially fed intoa hopper 10 that in one embodiment is a feed hopper equipped with ascrew conveyor or paddle screw feeder that is adapted to controllablyfeed biomass to a feed conveyor 14. In another embodiment, the biomassis fed directly into a surge bin 18.

A feeder 22 positioned beneath the feed hopper 10 empties biomass ontothe conveyor 14. In one embodiment, the feed conveyor 14 provides up to6000 pounds (2721.6 kg) of biomass per hour to the surge bin 18. Thesurge bin 18 is equipped with a controllable feed screw 26 that suppliesthe desired amount of feed at the desired rate to the fluid bed reactor6. In another embodiment, a rotary valve or lock hoppers may be used ifthe surge bin is located above the reactor 6. In one embodiment, thesurge bin 18 employs low level and high level sensors that automaticallycontrol a rotary valve and/or associated feeder 22 located underneaththe feed hopper 10 in order to maintain a predetermined amount of feedbiomass in the surge bin 18. In another embodiment, the level of biomassin the surge bin 18 is controlled using a continuous level sensor suchas, e.g., an ultrasonic level sensing unit. A feed screw 26 directsbiomass to the fluid bed reactor 6. The fluid bed reactor 6 may be acustom design or a commercially available design.

The biomass can be dried to a moisture content of less than about 20weight percent before introduction to the reactor 6. The biomass may bepre-dried by conventional means including, e.g., air drying, rotarykilns, cascaded whirling bed dryers, elongated slot dryers, hopperdryers, traveling bed dryers, vibrating fluidized bed dryers, and othermethods that do not employ a fluidized bed reactor. Those of skill inthe art will appreciate that fluidized-bed dryers or reactors may alsobe used. The heat source for pre-drying the biomass may be of the formof waste heat, other available heat sources, or auxiliary fuels. Thewaste heat may be drawn from the reactor 6 or an emissions controldevice 102. In one embodiment, the biomass is pre-dried to a moisturecontent of about 5 to about 20 weight percent. In another embodiment,two or more biomass materials, each with different moisture contents,are blended together to provide a raw feed with an average moisturecontent of less than about 40 weight percent that may also have beenpelletized before processing.

FIG. 3 is a schematic of an integrated fluid bed reactor 6 and pre-dryersystem of one embodiment of the invention. Off-gases 46 from thefluidized bed 6 are recycled and re-enter the fluid bed below plate 34.The fluidized bed reactor 6 is cylindrical and has an aspect ratio (bedheight divided by diameter) of about 2 or less, in one embodiment, theaspect ratio ranges from about 2 to about ⅓. Non-cylindrical fluidizedbeds also may be used, but in one embodiment, the aspect ratio thereof(the ratio of the bed height to the maximum cross sectional dimension)ranges from about 2 to about ⅓. Bed fluidization is achieved bydirecting fluidizing gas through the perforated plate 34. A mixture offresh air and recycled gas, i.e., gas taken from the fluidized bedreactor 6, is used as the fluidizing gas. It is preferred to use ablower to control the amount and composition of the fluidizing gas. Inother embodiments, multiple blowers may be used or flow control devices.

A startup heater system 110 is used to provide the heat needed forpreheating the fluidizing gas during startup and for flame stabilizationduring normal operation. In addition, a recycle fan 54 is used to movethe fluidized gas in a loop comprised of lines 58, 62, 66, 70, 74, 78,82, 86 and 90 during startup and shutdown of the system.

A fresh air fan 94 or the burner fan 50 is used to add fresh air to thefluidizing gas in order to adjust the oxygen content thereof. In anotherembodiment, the fan 94 may be replaced with a control valve and asuitable control valve added to line 86. During startup and shutdown, asfresh air is added to the fluidizing gas, a vent valve 98 is used torelease an equal amount of gas to the emissions control device 102 tomaintain a consistent flow of fluidizing gas through the reactor 6.

Gases exiting the reactor 6 enter a particulate removal device 106 wherefines are separated. Multiple fines removal devices may be employed toallow coarser particulate to be recovered as additional product or as aseparate product. Cleaned gas passes a vent valve 98 where anappropriate amount of gas is vented to an emissions control device 102.The purpose of the emissions control device 102 is to destroy anycarbonaceous components in the offgas after removal of particulate. Theemissions control device could be, e.g., a thermal oxidizer.Alternatively, the emissions control device could be, e.g., a catalyticoxidizer. Extra fuel may be added to the venting gas to raise thetemperature thereof. The gas exiting the emissions control device wouldbe a source of waste heat for drying the feed in the pre-dryer (notshown).

In one embodiment, a typical startup procedure involves, e.g., startingthe heater system 110 and the recycle fan 54. Recycle fan speed isselected to ensure sufficient gas flow to achieve bed fluidization,preferably the apparent gas velocity in the reactor is in the range ofabout 4 to 8 feet per second. The temperature of the fluidizing gas isslowly increased using the heater system. When the biomass in thereactor 6 reaches a temperature within the range of about 446 to 482° F.(230 to 250° C.), biomass is fed to the reactor to fill the reactor bed.When the biomass reaches a temperature of approximately 250° C. (480°F.), it begins to release heat as it consumes oxygen present in thefluidizing gas. Small amounts of biomass are then added to the reactor 6to maintain a steady rise in the temperature of the fluidized bed. It ispreferred that the temperature of the fluidized bed be maintained atabout 230 and 350° C. (450 to 670° F.) and, more preferably, about 270to about 300° C. (520 to about 570° F.).

As biomass is processed it exits reactor 6 through valve 114 into acooler 118. A dump valve 122 can be used to remove material buildup inthe bed, or in case of emergency, be actuated to quickly empty thereactor 6 contents into the cooler 118. As the process reaches steadystate, the temperature of the recycle gas in line 66 increases and theburner system 110 controls automatically reduces the firing rate. In oneembodiment, hot gasses taken from the emissions control device 106 areused to preheat the fluidizing gas (for example, by the process of FIG.3) to reduce the amount of combustion of biomass required to maintainthe temperature of the fluidized bed as well as the amount of fuelrequired by the burner system 110. The reactor 6 is preferably equippedwith several water spray nozzles (not shown) to assist in the controlthe temperature of the fluidized bed. The reactor 6 is also preferablyequipped with several temperature sensors to monitor the temperature ofthe fluidized bed.

At steady state, reactor 6 operation is a balance between biomassparticle size, the reactor temperature, the residence time required fordecomposition of biomass polymers, the residence time required formoisture to diffuse from the interior of the biomass particles, thereaction rate of oxygen with the volatile organics, and the gas velocityrequired for maintaining proper levels of fluidization. In oneembodiment, the smallest biomass particle dimension is from about 3 mmto about 10 mm, the fluidizing gas velocity is from about 4 to about 8feet per second, the temperature of the fluidized bed is maintained atabout 230 and 350° C. (450 to 670° F.) and, more preferably, at about270 to about 300 degrees ° C. (520 to about 570° F.), and the averagebiomass particle residence time is from about 5 minutes to about 30minutes.

The gases leaving the reactor 6 via line 82 have an oxygen content ofless than about 8 volume percent, whereas the oxygen content of thefluidizing gas is maintained at about 10 to 14 volume percent tomaximize the rate of biomass processing. At the preferred steady stateconditions, the amount of heat released via the combustion of thebiomass is balanced by the amount of heat required to accomplishtorrefaction and dry the biomass added to the reactor 6.

The off gas from reactor 6 is run through a particle separation step toremove particles entrained in the reactor offgas. In one embodiment,this step consists of a single unit such as a cyclone 106. In anotherembodiment, the particle separation step includes multiple devices tofacilitate recovery of entrained particles on the basis of particle sizeor density. Larger particles may be directed to the reactor dischargefor recovery as product.

The biomass produced in reactor 6 is typically at a temperature of about275 to about 330 degrees Centigrade, and it typically contains about 0to about 1 weight percent of moisture. This product is dischargedthrough valve 114 which may be, e.g., a rotary valve, lock hoppers, etc.to a cooling apparatus 118.

In one embodiment, the torrefied biomass could be used at locations nearthe production site. In this embodiment, the torrefied biomass wouldneed to be cooled below its combustion temperature. The preferred methodfor cooling occurs in one process piece of process equipment. This couldbe a screw conveyor, a mixing screw conveyor, a rotary drum, rotary tubecooler or any other device that would provide cooling through heatlosses to ambient or the application of water. The cooler 118 would beequipped with a multiplicity of water sprays and temperature sensors toallow water to be applied to the product for either progressivelylowering the temperature of the product to less than about 100 degreesCentigrade at sea level and/or adding up to about 3 percent moisture tothe product. The application of water may be continuous or intermittent.The control of water application could be on the basis of temperature,the mass flow rate of product and/or a combination thereof.

In one embodiment, the cooling device would be a mixing screw. Inanother embodiment, the cooling device could be a hollow flight screwcooler. The screw cooler assembly is also comprised of a multiplicity ofwater sprays and temperature sensors to control the application of wateron the basis of product temperature. For example, if the rate oftemperature decrease in the cooler is too high, the rate may be modifiedby modifying the biomass feed rate into the system, and/or by modifyingflow rate or temperature of the water in the screw jackets and/or therate at which water is applied using the sprays. The water spray may becontinuous, and/or it may be intermittent.

The cooled biomass from cooler 118 is discharged 70 to a conveyor 126.The conveyor 126 conveys the cooled biomass product to a storage system130, a load out system for trucks or railcars (not shown), or directlyto the end user. Any gases emitted in the cooler are directed to theemissions control device 106.

In another embodiment of the present invention the torrefied biomassdischarged from the reactor is densified to facilitate long distancetransport and/or long term storage. To facilitate densification, thetorrefied biomass is not cooled which maximizes the effectiveness ofresidual binders in the torrefied biomass. The densification equipmentwould be well insulated and close coupled to the reactor discharge toavoid excessive heat loss. In another embodiment the densificationequipment would be heated using jacked equipment.

The torrefied biomass discharged is directed to a grinder 140, which maybe any number of devices such as a jaw crusher, roller mill, or hammermill. Selection of the grinder would be a function of the requirementsof the densification device 144. The densification device of oneembodiment of the present invention is a pellet mill such as thatproduced by various vendors such as Andritz-Sprout, Bliss Industries, orAmandus Kahl that is modified to operate at temperatures in the range ofabout 90° C. to about 200° C. In another embodiment, the densificationdevice is a roll press similar to that produced by Komarek. In yetanother embodiment, the densification device is comprised of emergingpress technology such as that being developed by Kanvironmental. Both ofthese latter contemplated embodiments would require operation in therange of about 90° C. to about 200° C.

In another embodiment, supplemental binders are added beforedensification. For example, the binder may be at least one ofunprocessed lignin, lingo-sulfonate, coal, bitumen, molasses, or rawbiomass. These binders are added to the ground torrefied biomass in amixer (not shown) such as a pug mill, ribbon blender, static mixer, ormixing screw.

After densification, the pellets or briquettes are cooled to providestrength for subsequent handling, storage, and transport. The coolingdevice 146 would cool the pellets (or briquettes) to a temperature ofabout 50° C. The cooling device would directly contact the pellets withair or an inert gas through the use of an external fan 150. The coolingstep may also include a gas cooling system (not shown) to facilitate therecycle of the cooling medium or to enhance the functionality of thecooling step.

Referring now to FIG. 4 shows a Proximate and Ultimate analysis for anexample woody biomass feed. FIG. 5 shows a Proximate and Ultimateanalysis for the torrefied product produced from the woody biomass feedof FIG. 4.

FIG. 6 represents four processing path options for the reactor product,i.e., the torrefied biomass. The right arrow represents directing thetorrefied biomass to an insulated holding tank where it would be thendirected to the grinding and pelletizing operation. In this option,supplemental heating of the material would be required to keep thematerial at the desired pelletizing temperature. The down arrowrepresents directing the torrefied biomass directly to the grinding andpelletizing operation. As there is the potential of heat loss to theenvironment during grinding, supplemental heating of the grindingequipment may be required to keep the product at the desired pelletizingtemperature. The left arrow represents directing the torrefied biomassto a briquetting machine. If it is necessary to grind the reactorproduct before briquetting, supplemental heat may also be required tomaintain the temperature of the product. The up arrow representsdirecting the torrefied biomass to a mixing operation where supplementalbinders could be added. After the addition of the binder, the dischargefrom this operation would be re-directed to one of the first threeprocessing steps described above.

While various embodiments of the present invention have been describedin detail, it is apparent that modifications and alterations of thoseembodiments will occur to those skilled in the art. However, it is to beexpressly understood that such modifications and alterations are withinthe scope and spirit of the present invention, as set forth in thefollowing claims.

What is claimed is:
 1. A process for biomass torrefaction, comprising:adding biomass to a reactor; adding a first gas to said reactor, whereinthe first gas comprises an oxygen concentration from about 10 vol % toabout 21 vol %; controlling an oxygen concentration of a second gasexiting said reactor, wherein said oxygen concentration of the secondgas is less than about 8 vol %; initiating heating of said biomass byincreasing a temperature of said reactor; heating said biomass to abiomass temperature between about 250° C. to about 325° C. by partialcombustion of said biomass with oxygen in the first gas in said reactor;maintaining the biomass temperature within said reactor for apredetermined time by spraying water into said reactor, whereby aportion of moisture is removed from said biomass, volatile organiccompounds associated with said biomass are removed, and said biomass istorrefied to produce a torrefied biomass with a moisture content fromabout 0 wt % to about 2 wt %; and increasing the density of saidtorrefied biomass at a temperature of about 90° C. to 200° C. to form adensified biomass.
 2. The process of claim 1, wherein said densifiedbiomass is hydrophobic.
 3. The process of claim 1, wherein saiddensified biomass has a glassy surface.
 4. The process of claim 1,wherein said densified biomass contains a distribution of lignins. 5.The process of claim 1, wherein said densified biomass possesses acoating.
 6. The process of claim 1, wherein said densified biomass is inthe form of pellets or briquettes.
 7. The process of claim 6, whereinthe pellets have a maximum size of about 1.5 in.×1.5 in.×0.4 in.
 8. Theprocess of claim 1, wherein binders are not added to the torrefiedbiomass.
 9. The process of claim 1, further comprising adding a binderto the torrefied biomass.
 10. The process of claim 1, further comprisingfeeding said torrefied biomass directly to a densification device,wherein the temperature of the torrefied biomass is maintained.
 11. Abiomass pellet made by the process of claim
 1. 12. A single-stageprocess for biomass torrefaction, comprising: charging biomass to afluidized bed reactor, said biomass selected from the group consistingof wood, forestry waste, energy crops, municipal waste, plant material,straw, agricultural waste, and combinations thereof; charging afluidizing gas to said fluidized bed reactor at a velocity of from about4 to about 8 feet per second; combusting an amount of said biomass insaid fluidized bed reactor; spraying liquid water into said fluidizedbed reactor to assist with control of a temperature of said fluidizedbed reactor from about 230° C. to about 350° C.; maintaining an oxygencontent of less than about 15 vol. % in an exiting gas leaving saidfluidized bed reactor; removing moisture from said biomass, wherein saidbiomass charged to said fluidized bed reactor has an average moisturecontent of from about 10% to about 50%, and wherein said fluidized bedreactor is comprised of a fluidized bed with a fluidized bed density offrom about 20 to about 50 pounds per cubic foot, whereby a torrefiedbiomass is produced; and increasing the density of said torrefiedbiomass at a temperature of about 90° C. to 200° C. to form a densifiedbiomass.
 13. The process of claim 12, wherein said densified biomass ishydrophobic.
 14. The process of claim 12, wherein said densified biomasspossesses at least one of a coating and a glassy surface.
 15. Theprocess of claim 12, wherein said densified biomass contains adistribution of lignins.
 16. The process of claim 12, wherein saiddensified biomass is in the form of pellets or briquettes.
 17. Theprocess of claim 12, further comprising adding a binder to the torrefiedbiomass.
 18. The process of claim 15, further comprising feeding saidtorrefied biomass directly to a densification device, wherein thetemperature of the torrefied biomass is maintained.
 19. The process ofclaim 12, wherein the pellets or briquettes have a maximum size of about1.5 in.×1.5 in.×0.4 in.
 20. The process of claim 12, wherein atemperature of the reactor is between about 270° C. and about 300° C.